Manufacture of sponge rubber



Aug. 7, 1945. M. CARTER MANUFACTURE OF SPONGE RUBBER Filed Dec. 19, 1940 fig. 1,

' lkoTHIN A RUEla lLspLs'lo/v l A/NGAm/www/ MTR/1 71E 75 @E [kof/1 PLA cl/v THE 157207111 /NA Wwe/11 Maw LL//v THE F4202?! 7b FORM /l/v AAZTIOLE HAU/1N@ A E/VSE JUSmNTfALLy/PEM ma@ @SURF/10E INVEN-ron BY mitchell cada* f a# ATTO RN EY v Patented Aug.4 7, 19.45 'v .l

v MANUFACTURE z,3s1,sso

.oF sroNGE RUBBER Mitchell Carter, Trenton, N. J., lrestone Tire 'Rubber Ohio, a corporation of Ohio y Application December 19, 1940, scr-Inno. 370,191

' (cl. 1s53) 6 Claims.

v'uns invention relasvm celluiarjorsponge, rubber, especially tothe production of cellular rubber articles and to methods of manufacturing same. Y

YHeretolfore .many various methods have been proposed by `which sponge rubber articles can be made. One important method of `manufacturing sponge rubber from latex involves the use of stabilizing. and frothing ingredients. These substances, plus a delayed action gelling agent, are added to the latex, after which the latex is mechanically whipped or aerated to form a froth. Then it is poured into molds and after aA short interval the latex froth is gelled due to the effect of the delayed action gelling agent therein. This delay occurring before the frothed latex is gelled permits some of the froth to break down before it is solidified. Hence, irregularities frequently occur in the resultant product. In s'me instances, the delayed action gelling agent may'not function satisfactorily and it may produce gelation either during the frothing of the latexor else it may fail to set up the frothed latex until after a large portion of the froth has broken down. The gelling of latex froth, in most cases, forms imperviousskins around the resultant sponge rubber and in general is not entirely satisfactory. This is especially true in producing some specific sponge articles, such as toys and other sponge articles which should have a dense, but soft, substantially impervious surface.

In the accompanying drawing Figures 1 and 3 are flow diagrams illustrating the invention, and

Figure 2 is a section through a toy made in accordance with the invention.

The general object of the present invention is to provide an improved method of forming sponge rubber, and, specifically: to provide a novel way of gelling latex froth; to provide a latex which is compounded to prevent overcure thereof; to control the cell size of frothed latex; to form a cellular rubber of greater strength than that obtained by ordinary vulcanization methods; to provide a novel method of forming rubber articles from two types of rubber; to provide an improved l molding method for forming irregularly shaped articles; and to provide a method of forming rubber articles having voids in the center thereof.

The foregoing and other objects will be manifest as the specifications proceeds.

vIn practicing the present invention, dispersions of rubber, synthetic rubber, or rubber-like substances may be used. These dispersions may be either naturally or artificially created and may have dispersed rubber particles that are either vulcanized or unvulcanized. 'I'he invention will be described with reference to natural latex.

The latex used, which preferably is concentrated to a solids content of about 57%, is frothed in any desired manner as by beating and/or aerating same in a container. Preferably, after the latex is frothed; the desired compounding ingredients are added thereto.

One example of the invention comprises frothing 100 parts (dry weight) of 57% solids content latex to the desired volume and then adding a master batch thereto. This master lbatch comprises:

Parts-dry weight "Zenite (zinc mercaptobenzotlnazole) 1.00 Pip-Pip (piperidinium pentamethylene dithiocarbamate) 1.00 Ethyl-zimate .25 Sulfur 1.50 Zinc oxide 3.60 Baking powder 4.40 Stablex B (a sulphonated naphthalene derivative) .20 Ammonium nitrate .30 Ammonia (NH3) 1.28

Total 13.53 Water 9.85

The master batch may be made up in bulk using, in most icasts, ball mill dispersions of the dry ingredients. The Zenite, Pip-Pip, ethyl zimate and zinc oxide are ball milled with 3% of Darvan #1, While the sulfur is ball milled with 3% of Daxad #27. 'I'he amonium nitrate and Stablex B are added to the master batch as 50% water. solutions andthe ammonia. is added as a 28% solution. The baking powder which comprises, roughly, 50% sodium bicarbonate, 25% sodium aluminum sulfate, and 25% calcium acid phosphate, is stirred into the master batch after the ammonia is added.

After the latex has been frothed and the compounding ingredients mixed therewith, the frothed latex is poured into suitable molds to form the desired sponge rubber articles. The molds are heated to a. temperature between and 99 C. before the froth is poured therein. These hot molds, together with the use of ammonium nitrate in the frothed latex, cooperate to gel the latex froth before the entrained air in the cells swells to enlarge or break the cells. This gel is formed quite rapidly immediately adjacent the mold surfaces and the main bulk of latex froth is gelled within a short time thereafter, whereby the desired article is formed. Dueto the rapid gelation of the surface froth, a densebut porous and smooth surface is formed on the rubber article. This surface increases the life of the resulant article and improvesl the appearance thereof. In this embodiment of the invention a blowing action is effected when the latex froth is placed in the hot mold whereby the froth is urged out to iill the mold completely.

Small simply formed rubber articles which are gelled hard when heated molds are used, frequently can be removed shortly after gelation occurs and subsequently be vulcanized in open steam or hot water. Hence the molds can be turned over much more rapidly than if the articles are vulcanized while in the mold.

Ordinarily the latex froth is vulcanized immediately after it has been gelled, which action is secured by raising the temperatureV to which the froth is subjected. In the example given, the latex frothis compounded in such a manner that the gelation temperature will vulcanize the latex rubber obtained. Small articles have been vulcanized by an hour to an hour and twenty-five minutes exposure to the gelling temperature.

Figure 1 illustrates the steps of the method of the invention required to produce a cellular rubber toy I0, which is shown in section in Figure 2. The toy I0 has small, densely associated cells Il adjacent its outer surface which is durable and only slightly pervious and'thereby is adapted to be painted without using an excessive quantity of paint. 'I'he cells in the toy Ill become gradually larger in towards the toys center until large cells l2 are formed at the center of the toy. In some cases, the toy I0 may be dipped in latex to form a totally impervious skin thereon. The baking powder used in the invention releases gas substantially continuously during the vulcanization of the cellular rubber used in making the toy I0. This aids in retaining the rubber in contact with the entire mold surface to produce a perfectly formed molded article. The baking powder seems to aid the ammonium nitrate, or any other similar class gelling agent used, such as ammonium sulfate, in obtaniing the desired gelling action. Figure 3 covers a more specific aspect of the invention than that of Figure 1.

The latex used in practice of the` invention has been bulked, blended, and standardized in accordance with the disclosure in my copending application Serial No. 370,790, filed December 19, 1940, and has a mechanical stability of about 430,

,I as determined in said application.

When a sponge rubber of enhanced tensile strength is desired, the latex froth should be compounded in such a manner that vulcanization will not occur at low temperatures. In that instance, vulcanizing agents that start vulcanization only at elevated temperatures should be substituted for the accelerators used in the usual practice of the invention. Only a minimum quantity of zinc oxide and accelerator should be present in the latex. Then the latex froth, after being poured into the Warm molds, is placed in a vulcanizing chamber maintained at atmospheric pressure and at the highest practical temperature to dry the rubber. Of course, the temperature of the rubber will not rise above the temperature of boiling water as long as any water remains in the rubber. The pressure in the vulcanizing chamber should be such that the boiling temperature of Water is not high enough to start appreciable vulcanization of the rubber. The frothed latex is exposed to such temperature and pressure for a sufficiently long time to gel the froth completely and allow communication between the cells, whereby the air in the cells is replaced by vapor. Next, the vulcanizing chamber is filled with dry steam at the highest possible temperature at atmospheric pressure until the gelled froth is dry.v Finally, the dried latex rubber is vulcanized by introducing steam at a temperature appreciably above 100 C. to vulcanize the rubber. The vulcanized rubber obtained will be practically dry when cooled. If desired, the rubber obtained may be washed in the usual manner. Practice of this modification of the present invention produces cellular rubber of maximum tensile strength. This process gives especially good results upon sponge rubber made without the use of soaps or other foam forming and stabilizing agents.

The latex froth may also be gelled by heating it in a steam vulcanizing chamber to 212 F. until the latex is thoroughly gelled and the cell walls are sufciently broken that the cells intercommunicate. Then steam pressure may gradually be built up in the vulcanization chamber to vulcanize the froth rapidly. Obviously such pressure cannot be set up until the froth is thoroughly gelled and will not be collapsed thereby.

Heretofore cellular rubber articles have been formed in molds all of which Were provided with some kind of a cover. In applying the cover to a mold it is almost impossible to keep from trapping air in the mold whereby the article obtained may have a rough, poorly finished surface and may not be suitable for use. It has been established that latex froth can be gelled in an open mold to produce an article of the desired shape. Preferably the mold is warmed to aid in gelling the latex froth, as pointed out hereinabove. After a rubber gel is formed, which gel may be formed by placing the mold in a vulcanizing chamber containing water vapor at about 180 to 210 F., the rubber is vulcanized by continued exposure to the water vapor or by placing the mold in open steam, hot water, or other vulcanization medium. The froth placed in the mold may swell or expand slightly before it is completely gelled and vulcanized, depending upon the temperature of the mold and/or vapor, the size ofthe article, amount of gelling agent used, etc., but such swelling can be readily controlled by reducing the gelling time. In all events, the exposed surface of the latex froth will be formed into a smooth, uniform rubber surface of good appearance and none of the surface froth will break down before gelling.

In some cases, it may be desirable to substitute the following ingredients for the compounding and vulcanizing master-batch listed above:

Percent Zinc oxide .03 Flowers of sulfur 1 Pip-Pip .25

dispersed in water containing a small percentage of Stablex B. This compounded latex is particularly resistant to overcure and may be subject to vulcanizing temperatures for many extra hours without being overcured excessively. Latex compounded in this manner is especially adapted for use in forming rubber molds which are subjected to vulcanization temperatures to vulcanize rubber contained therein, or it may be used in forming rubber articles of intricate shape which are Ibuilt up from several sections, each of which is vulcanized after being placed on the article being formed.

Occasionally one may wish to increase the cell size of the latex froth before it is completely gelled, or, at least, before the froth is vulcanized. This cell enlargement may be done chemically by adding ammonia to the latex, either before or after the latex is frothed. For example, about 1% of ammonia, relative to the latex, may be added to the froth, which ammonia will be vaporized when the froth is placed into a warm mold. The ammonia gas produced rapidly expands upon heating and will enlarge the cell size in the froth before the cells are broken. Hence it causes the latex froth to swell out and ll the mold completely when the mold is initially filled with latex froth to, say, about 85% of its capacity. An additional quantity of gelling agent should be used to obtain rapid setting of the-froth to retain the generated gas therein while the swelling is taking place.

In a modiflcation of the present invention, stiff rubber articles can be produced. In this instance, latex froth is formed as described hereinabove and introduced into warm molds as in the practice of the iirst described method. After this frothed latex is poured into warm molds, it is allowed to stand in the molds until a cellular rubber wall of the desired thickness has been formed on the mold surface. I'hen the surplus latex froth is removed by any suitable method and the mold is placed in a vulcanizer for a few minutes to gel the froth completely. r, if the mold contains sumcient heat to cause thorough gelling, the latex froth merely may be allowed to stand in the mold until completely gelled. To reinforce the cellular rubber walls formed in the molds, unaerated heat-sensitized latex is poured into the mold and allowed to stand until the desired thickness deposit thereof has been obtained on the inner surface of the cellular rubber deposit in the mold. During this operation if the heat contained in the mold is not sufficient to gel the latex rapidly, the mold should be heated in some manner to effect the coagulation or deposition of the latex on the cellular rubber. 'I'he remaining liquid latex in the mold now may be poured, or drawn, therefrom and the rubber .article within the mold is vulcanized in any suitable manner. This article formed will have a sponge rubber outer surface and a solid rubber whereby a stiff rubber figure formed apparently from sponge rubber, is provided. In the same manner, it is possible to form protective coatings of synthetic rubber upon sponge rubber. That is, a latex made from Neoprene, Thiokol or other sunor oily-resistant rubber-like material is made, which latex preferably is heatsensitized, and the latex is poured into a heated mold to deposit the rubber-like material on the mold. As soon as a layer of the desired thickness is deposited, the remaining latex is drawn or poured from the mold. Substantially immediately natural latex froth is introduced into the mold and gelled to form the desired article which then is vulcanized in any suitable manner.

When the synthetic rubber coating is to be placed on an article formed in an open mold, as outlined hereinabove, a coating of the synthetic can be poured, sprayed, or even brushed onto the latex froth after it has been thoroughly gelled and has been heated to a temperature suiicient to gelv the synthetic vlatex applied thereto. In all events, the two latices must be associated before either latex has shrunk after being gelled and the water contents of the two latices must be substantially equal to give the rubber produced therefrom uniform shrinkage. Obviously the latices should be compounded to have substantially the same vulcanization characteristics. It has been found that in filling mold cavities of intricate shape, it is dsirable to ll these molds from the bottom. This is done by pressure or gravity feed. wherein latex is fed into the bottom of the mold and a slight vent is provided at the top of the mold as well as in the top of recesses in the mold which are diiilcult to illl in order to prevent trapping air within the mold after the latex is forced into the mold cavity. This insures filling the mold cavity completely with latex, which thereafter can be processed in accordance with standard practice.

Cellular rubber articles having large single voids in the interior thereof can be produced without the use of a core by forming froth in accordance with the invention and placing the same in a warm substantially annular mold. Next a hollow tube is inserted into the mold with the end of the tube being at the center or other desired point in the article to be vulcanized.A The tube connects the interior of the mold to the atmosphere. Then the mold is placed in a vulcanization chamber and steam at the desired pressure and temperature is fed into the vulcanizer, which steam passes through the tube leading into the mold and sets up sufiicient pressure within the mold to make an enlarged cavity in the center of the latex froth in the mold. This action results because the portion of the latex froth in contact with the mold, which is heated before the froth is poured therein, has gelled rapidly after its introduction into the mold.

Then the liquid latex froth in the interior of the mold is forced out substantially uniformly against the gelled latex froth at the mold surfaces to increase the density and wall thickness of the cellular rubber article formed.

From the foregoing it should be apparent that a novel and improved method of forming cellular rubber is provided by the invention and that Athe objects ofthe invention have been achieved.

In the embodiments of the invention illustrated and described herein, it will be apparent that various minor changes can be made thereto without departing from the scope of the invention as defined in the appended claims.

` What is clamed is:

l. 'I'hat method of producing cellular rubber comprising the steps of frotliing a rubber dispersion, mixing compounding ingredients with the rubber dispersion to vulcanize the rubber but to prevent; its vulcanization from starting below about 99 C., admixing baking powder and ammonium nitrate with the frothed dispersion, placing the frothed dispersion in a mold heated to between to 99 C. whereby immediately to `gel the dispersion, adjacent the mold surface,

persion at a temperature appreciably above 99 C.

3. 'I'hat method of producing cellular rubber comprising the steps of frothing a rubber dispersion, adding baking powder and a gelling agent to the frothed dispersion and mixing it therewith, placing the frothed dispersion in a hot mold having a temperature of 85-99 C. whereby immediately to gel the dispersion adjacent the mold surface, and gelling the remainder of the dispersion to obtain a porous rubber article having a smooth dense porous surface thereon.

4. That method of producing cellular rubber comprising the steps of frothing a rubber dispersion, adding baking powder and ammonium nitrate to the frothed dispersion and mixing it therewith, placing the frothed dispersion in a hot mold wherebyimmediately to gel the dispersian adjacent the mold surface, gelling the remainder of the dispersion, and vulcanizing the gelled frothed dispersion in the presence of .03% zinc oxide, 1% sulfur and .25% piperidinium pentamethylene dithiocarbamate and no other vulcanizng ingredients.

5. A method of forming small simply contoured molded cellular rubber articles from latex, comprising the steps of compounding latex with vulcanizing ingredients of a type and in an amount, which prevent its vulcanization from 2,ss1,sao

starting below about 99 C., frothing the latex, positioning the frothed latex in a mold heated to a temperature of 85-99 C. to gel the latex, removing the gel from the mold, and vulcanizing the gel.

6. In a method of forming cellular rubber articles having a smooth dense substantially impervious surface, the steps of frothing a rubber dispersion, admixing a masterbatch comprising zinc mercaptobenzothiazole, piperidinium pentamethylene dithiocarbamate, ethyl zimate, zinc oxide, sulfur, baking powder, and a gelling agent with the froth in proportions suited to prevent the vulcanization of the froth from starting below about 99 C., placing the compounded froth in a mold heated to 85-99" C. whereby the surface of the froth is gelled rapidly to form a smooth relatively dense substantially impervious layer of cellular rubber and the interior of the froth forms a gel of rubber having larger cells than the surface layer, and thereafter heating the rubber above 99 C. to vulcanize same.

MITCHELL CARTER. 

